Hot-fill plastic containers and method

ABSTRACT

A hot-fill plastic container has a polygonal (e.g., hex-shape) sidewall portion and a plurality of panels in a sidewall portion that are configured to flex in response to an internal vacuum pressure. Further, in embodiments, the container may be suitable for hot filling while having a container weight that may be 20% to 30%, or even higher percentages, below current comparative conventional weights for a plastic container that is intended to hold an equivalent volume of contents. In embodiments, the panels may be configured, e.g., adjusted or “tuned,” to provide a desired (e.g., reduced or extended) shelf-life.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of priority to U.S. Provisional Application No. 62/721,800, filed Aug. 23, 2018, the entire disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to plastic containers, including hot-fill plastic containers and methods for making hot-fill plastic containers.

BACKGROUND

This background description is set forth below for the purpose of providing context only. Therefore, any aspect of this background description, to the extent that it does not otherwise qualify as prior art, is neither expressly nor impliedly admitted as prior art against the instant disclosure.

Plastic containers are used in hot-fill applications—e.g., to store contents that are filled at an elevated temperature, and are permitted to cool. During the hot filling process, a heated liquid content may be introduced to a plastic container. The heated liquid can displace air within the container. As the heated liquid cools, the liquid may become more soluble for air, and may draw trapped internal air in the container back into the liquid contents—which can create an additional internal vacuum. Also, as product contents sit on a shelf for a period of time, there is a phenomenon, known as water vapor transmission loss (WVTL) that can occur, for example, in connection with polyethylene terephthalate (PET) containers. With WVTL, water trapped inside of the container can migrate out of the container over the course of the product shelf-life. Such a situation can be more challenging with lighter weight containers, lightweight plastic containers may have comparatively thinner wall thicknesses (at least in portions thereof), and a WVTL rate for a container is related to material thickness.

There is a desire for solutions/options that help to address one or more challenges associated with hot-fill plastic containers, including lightweight plastic hot-fill containers, which may be comprised of PET. The foregoing discussion is intended only to illustrate examples of the present field and should not be taken as a disavowal of scope.

SUMMARY

A hot-fill plastic container may have a polygonal (e.g., hex-shape) sidewall portion and a plurality of panels disposed in the sidewall portion that are configured to flex in response to an internal vacuum pressure. Further, in embodiments, the container may be suitable for hot filling while having a container weight that may be 20% to 30%, or even higher percentages, below current comparative conventional weights for a plastic container that is intended to hold an equivalent volume of contents. In embodiments, the panels may be configured, e.g., adjusted or “tuned,” to provide a desired (e.g., reduced or extended) shelf-life.

The foregoing and other aspects, features, details, utilities, and/or advantages of embodiments of the present disclosure will be apparent from reading the following description, and from reviewing the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view generally illustrating an embodiment of a plastic container according to aspects and/or teachings of the present disclosure.

FIG. 2 is a front elevation view of the embodiment of a plastic container as shown in FIG. 1, shown before hot-fill.

FIG. 3 is a cross-sectional view of a portion of the plastic container taken at A-A in FIG. 3.

FIG. 4 is a side elevation view of the embodiment of the plastic container shown in FIG. 1, shown post hot fill.

FIG. 5 is a bottom plan view of the embodiment of the plastic container that is shown in FIG. 1.

It is noted that dimensions and/or tolerances included with the figures are for the purposes of illustrating an embodiment of the present disclosure, and the invention is not limited to the specific dimensions and/or tolerances provided.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the present disclosure will be described in conjunction with embodiments and/or examples, it will be understood that they are not intended to limit the present disclosure to these embodiments and/or examples. On the contrary, the present disclosure is intended to cover alternatives, modifications, and equivalents.

An embodiment of a plastic container 10 according to aspects and/or teachings of the present disclosure is generally illustrated in FIG. 1. A 20 oz. container is generally shown in the drawings. However, those of skill in the art will recognize that that the disclosure is not limited to such a specific size and/or configuration of a container. Further, by way of example and without limitation, a 20 oz. hot-fill container, such as generally illustrated in the figures, may have a weight of about 23.2 grams±0.6 grams.

Front and side elevation views of the embodiment of a plastic container are shown in FIGS. 2 and 4. In addition to representing different views, FIGS. 2 and 4 represent different time periods with respect to a filling process. It is noted that the dimensions and/or tolerances included in FIGS. 2, 3, and 4 are for the purposes of illustrating an embodiment of the present disclosure, and the invention is not limited to the specific dimensions and/or tolerances provided.

FIG. 1 generally illustrates an embodiment of a plastic container 10 that exhibits aspects and/or teachings associated with the present disclosure. The plastic container 10 may be comprised of a polymer, including one or more polymers that may be injection molded (e.g., into a preform) and/or stretch blow molded. In embodiments, the plastic container may be comprised of polyethylene terephthalate (PET), including various forms (e.g., virgin or recycled) or blends thereof.

As generally illustrated in FIGS. 2 and 4, embodiments of a plastic container may include a neck portion 20, a shoulder portion 30, a sidewall portion 40, and a base portion 70. The sidewall portion 40 may further comprise an upper sidewall portion 50 and a lower sidewall portion 60. At least a portion of the sidewall portion 40 of the plastic container 10, such as the lower sidewall portion 60, may have a polygonal shape.

As generally shown with respect to the embodiment illustrated in FIGS. 2 and 3, a plastic container according to aspects or teachings of the present disclosure may include an upper sidewall portion 50 that is generally cylindrical, and a lower sidewall portion 60 that has a hexagonal (“hex”) or generally hexagonal shape. In embodiments, the lower sidewall portion 50 and the base portion 60 may comprise at least 0.55 of the total height of the container 10. In embodiments, such as illustrated in FIG. 2, the lower sidewall portion 50 and the base portion 60 may comprise at least 0.57 of the total height of the container 10 (e.g., H1). Additionally, in embodiments, the height of the lower sidewall portion 50 and the base portion 60 combined together may be about 1.7 times the diameter of the base portion (e.g., D6).

With reference to FIG. 2, an embodiment of a container 10 in a pre-hot-fill condition may, for example and without limitation, have dimensions such as the following:

-   -   H1—8.304 in ±0.060 in (210.92 mm±1.52 mm)     -   H2—0.761 in (19.33 mm)     -   H3—0.750 in (19.05 mm)     -   H4—0.200 in ±0.025 in (5.08 mm±0.64 mm)     -   H5—7.555 in (191.90 mm)     -   H6—1.457 in (37.01 mm)     -   H7—4.763 in (120.98 mm)     -   H8—2.575 in (65.40 mm)     -   D1—1.299 in (33 mm)     -   D2—1.141 in ±0.025 in (28.98 mm±0.64 mm)     -   D3—2.800 in (71.12 mm)     -   D4—2.700 in (68.58 mm)     -   D5—2.800 in (71.12 mm)     -   D6—2.800 in ±0.060 in (71.12 mm±1.52 mm)     -   X—0.050 in (1.27 mm)

With reference to FIG. 3, which generally illustrates dimensions associated with the section view III from FIG. 2, an embodiment of a container 10 in a pre-hot-fill condition may, for example and without limitation, further include the following dimensions:

-   -   L1—2.460 in (62.48 mm)     -   L2—2.800 in (71.12 mm)

With reference to FIG. 4, an embodiment of a container 10 in a post-hot-fill condition may, for example and without limitation, have dimensions such as the following:

-   -   H9—8.296 in ±0.060 in (210.72 mm±1.52 mm)     -   D7—2.800 in ±0.060 in (71.12 mm±1.52 mm)

As generally illustrated in connection with embodiments shown in FIGS. 2 and 4, a post-hot-fill container (e.g., FIG. 4) may have a slight reduction in overall height as compared to the same container in a pre-hot-fill condition (e.g., FIG. 2)—i.e., the difference between H1 and H9. At the same time, the diameters associated with base portions 70 (e.g., D6 and D7) of the pre-hot-fill and post-hot-fill container may remain substantially the same. As generally illustrated in connection with FIGS. 2 and 4, in response to vacuum forces, a lower portion of the base portion 70 shown in FIG. 2 (e.g., shown with a diamond-like ring formation/pattern, see also, FIG. 5) may be pulled upwardly to a position such as generally illustrated in FIG. 4 (post-hot-fill). Such movement in response to vacuum force may, among other things, provide a small difference in the post-hot-fill and pre-hot-fill total height of the container as the base portion is reconfigured. Additional teachings associated with configurations for plastic containers, including those that address container base configurations and/or vacuum forces, is included in U.S. Patent Application Publication 2010/0163513 A1 (associated with U.S. patent application Ser. No. 12/648,647), which is incorporated herein by reference in its entirety, except for any inconsistent definitions, disclaimers, and disavowals, in which case the language and teachings of this disclosure controls.

In embodiments, such as generally illustrated, the upper sidewall portion 50 may include one or more structural reinforcing formations, which may, for example and without limitation, comprise one or more circumferential bands or ribs 80.

As illustrated, the lower sidewall portion 60 may include a plurality of panels 90 that may extend in a longitudinal direction and which can be configured to flex in response to internal pressures, such as internal vacuum pressure. In embodiments, panels 90 may generally extend between the upper sidewall portion 50 and the base portion 70. Also with embodiments, as generally illustrated, each panel 90 may include an upper curved portion 100 and/or a lower curved portion 110. In embodiments, for example as generally illustrated in the figures (e.g., FIGS. 2 and 4), the upper curved portions 100 and/or the lower curved portions 100 may curve downwardly and upwardly, respectively, toward the centerline of the individual panels. For example, the upper curved portion 100 may appear to drape from one end of a panel to the other end and the lower curved portion 110 may appear to curve/drape as a mirror image of the upper curved portion.

The panels 90 may further include one or more panel formations 120 that can control or affect the flexibility or flexing of a respective panel—for example, in response to an internal vacuum force, such as that encountered with hot-fill containers and the cooling associated with such container contents. For example, and without limitations, the panel formations 120 may comprise one or more ribs that extend in a circumferential direction across a portion of a panel 90.

With embodiments, such a unique configuration of the panels 90, such as generally illustrated, for example in a polygonal configuration, can permit lightweighting of similarly configured, similarly-sized containers. For example, plastic containers embodying aspects and/or teachings of the present disclosure may weigh about 20-30%, or even greater percentages, below current comparative conventional weights for a plastic container intended to hold an equivalent volume of contents. Moreover, such a weight reduction for hot-fill type plastic containers can be achieved without the utilization of secondary equipment. Further, the present disclosure can provide a plastic container having a portion (e.g., lower sidewall portion) with a polygonal shape, such as a “hex” or “hexagonal” shape, that can permit the container to compensate for vacuum pressures while increasing container strength as the panels flex.

Use of panels such as taught by the present disclosure can provide comparatively lighter weight plastic containers capable of more than one year of shelf life. That is, among other things, the teachings of the present disclosure can address and/or overcome common WVTL issues with super lightweight containers (i.e., containers that exhibit lightweighting reductions along the lines as previously mentioned). Moreover, the present disclosure is adjustable or scalable, as may be required or desired, to provide an intended amount of vacuum compensation. For example, if an intended product requires a long shelf-life, all sides (e.g., six panel sides for a hexagonal configuration) may be configured to accommodate (e.g., “pull in” in response to) vacuum forces. Alternatively, if a lesser shelf-life is intended or acceptable, an embodiment may involve a plastic container with a hexagonal portion having three panel sides configured to primarily accommodate vacuum forces, while the remaining three sides (which may be interspersed circumferentially therebetween—e.g., alternating) may be stiffened to reduce movement. Such stiffening may be effectuated, and the amount or degree of stiffening/strengthening controlled, for example, by adding or modifying strengthening formations with one or more panels and/or in an upper sidewall portion. In such a manner, a given hot-fill plastic container may be light weight and configured (adjusted or “tuned”) to meet an intended shelf life. In embodiments, the stiffening of a given panel may involve the inclusion of one or more formations or ribs (such as, for example, the ribs in the panels generally illustrated in FIGS. 1, 2, and 4).

Various embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to “various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.

It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of embodiments.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. The use of “e.g.” in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of “and” and “or” are to be construed broadly (e.g., to be treated as “and/or”). For example and without limitation, uses of “and” do not necessarily require all elements or features listed, and uses of “or” are intended to be inclusive unless such a construction would be illogical.

While examples of dimensions of certain components may be described herein, such dimensions are provided as non-limiting examples and the components may have other dimensions.

While processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that such methods may be practiced with the steps in a different order, with certain steps performed simultaneously, with additional steps, and/or with certain described steps omitted.

It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present disclosure. 

What is claimed:
 1. A hot-fill plastic container comprising: a neck portion; a shoulder portion; a sidewall portion; and a base portion; wherein the sidewall portion includes a lower sidewall portion; the lower sidewall portion, in cross-section, has a generally polygonal shape; and the lower sidewall portion includes a plurality of panels.
 2. The container of claim 1, wherein the lower sidewall portion, in cross-section, has a hexagonal shape.
 3. The container of claim 1, wherein the container is comprised of polyethylene terephthalate (PET).
 4. The container of claim 1, wherein the sidewall portion includes an upper sidewall portion, and the upper sidewall portion is generally cylindrical.
 5. The container of claim 1, wherein a central portion of the base portion is configured to flex up upwardly in response to vacuum forces.
 6. The container of claim 1, wherein the upper sidewall portion includes one or more structural reinforcing formations.
 7. The container of claim 1, wherein the upper sidewall portion includes one or more circumferential bands or ribs.
 8. The container of claim 1, wherein the plurality of panels extend between the upper sidewall portion and the base portion.
 9. The container of claim 1, wherein the plurality of panels include an upper curved portion or a lower curved portion.
 10. The container of claim 1, wherein the plurality of panels include an upper curved portion and a lower curved portion.
 11. The container of claim 1, wherein one or more of the plurality of panels include one or more panel formations.
 12. The container of claim 11, wherein the one or more panel formations include a formation that extends circumferentially across a portion of a panel.
 13. The container of claim 1, wherein the container includes at least six panels, and each panel includes a plurality of panel formations that extend circumferentially across a portion of each panel.
 14. The container of claim 1, wherein the container includes at least six panels and, in an alternating configuration, every other panel includes a plurality of panel formations that extend circumferentially across a portion of such panel.
 15. The container of claim 1, wherein the container, in an empty condition, has a weight of about 23.2 grams.
 16. The container of claim 1, wherein the container, in an empty condition, has a weight between about 22.6 grams and 23.8 grams.
 17. The container of claim 1, wherein the lower sidewall portion and the base portion comprise at least 0.55 of the total height of the container.
 18. The container of claim 1, wherein the lower sidewall portion and the base portion comprise at least 0.57 of the total height of the container.
 19. The container of claim 1, wherein the height of the lower sidewall portion and the base portion together is about 1.7 times the diameter of the base portion.
 20. The container of claim 1, wherein the base portion includes a circumferential diamond-like ring formation. 